The present disclosure relates generally to management of an energy storage device in a vehicle. More specifically, the disclosure pertains to a system and method for automated management of a dual-design battery pack. The use of mobile platforms employing a rechargeable energy source, both as an exclusive source of energy and a non-exclusive source of energy, has greatly increased over the last few years. An energy storage device with battery packs may store and release electrochemical energy as needed during a given operating mode. The electrochemical energy may be employed for propulsion, heating or cooling a cabin compartment, powering vehicle accessories and other uses. The various cells in the battery packs may be characterized by different charge states, power, and capacity rates. In a battery pack with a complex structure, management of the various parameters may be challenging.
Disclosed herein is a system for managing an energy storage device in an electric vehicle. The system includes a battery pack having an energy module, and a power module connected in parallel to the energy module. The energy module is adapted to generate a first current. At least one DC-to-DC (direct current to direct current) converter is adapted to receive the first current from the energy module and transmit a current, referred to herein as “DC-DC current”, to the power module. The system includes a controller having a processor and tangible, non-transitory memory on which instructions are recorded for automated management of a set of parameters related to the battery pack, subject to a plurality of constraints.
The power module is adapted to deliver a second current for powering a load in the electric vehicle. The energy module is adapted to selectively recharge the power module with a charging current after a predefined event of relatively high power demand. The set of parameters includes the DC-DC current, a first state of charge defined by the energy module, and a second state of charge defined by the power module. Operation of the electric vehicle is controlled based in part on the set of parameters.
The energy module and the power module may have different chemistries. In one embodiment, the energy module includes respective battery cells composed of nickel, cobalt oxide, and manganese. The power module may include the respective battery cells composed of lithium, iron, and phosphate. The electric vehicle may be adapted to undergo a first stage and a second stage. The first stage is associated with an initial acceleration mode and/or take-off mode of the vehicle, while the second stage being associated with a driving mode and/or cruising mode of the vehicle. The energy module may be adapted to recharge the power module during the second stage such that the energy module is a sole power source for the electric vehicle during the second stage.
The plurality of constraints may include: (1/n) [IC(t)−I1,MAX]≤IDC(t)≤(1/n) [IC(t)−I1,MIN(t)], where t is time, IDC is the DC-DC current, n is a number of phases of the DC-DC current, IC is the charging current, and I1,MIN and I1,MAX are respective minimum and maximum values of the first current. The plurality of constraints may include: [V2(t)/(n*V1(t))] [I2,MIN−IL(t)]≤IDC(t)≤[V2(t)/(n*V1(t))] [I2,MAX−IL(t)], where t is time, IDC is the DC-DC current, n is a number of phases of the DC-DC current, V1 and V2 are respective voltages of the energy module and the power module, IL is a load current transmitted to the load in the vehicle, and I2,MIN and I2,MAX are respective minimum and maximum values of the second current.
The plurality of constraints may include: IC(t)≤I1,MAX, where IC is the charging current, and I1,MAX is a maximum value of the first current. The plurality of constraints may include: ΔIC(t)≤D, where ΔIDC is an incremental change in the DC-DC current over time, and D is a predefined threshold. In one embodiment, the predefined threshold is about 1 Amperes. The DC-DC current may be between about 10 Amperes and 100 Amperes.
Disclosed herein is a method for managing an energy storage device in an electric vehicle having a controller with a processor and tangible, non-transitory memory, the energy storage device having a battery pack. The method includes incorporating an energy module and a power module in the battery pack. The energy module and the power module are connected in parallel. A first current is generated, via the energy module. The method includes adapting at least one DC-to-DC converter to receive the first current from the energy module and transmit a DC-DC current to the power module. The method includes managing a set of parameters related to the battery pack, via the controller, and subjecting the set of parameters to a plurality of constraints. The power module is adapted to deliver a load current for powering a load in the vehicle. The method includes adapting the energy module to selectively recharge the power module with a charging current after a predefined event of relatively high power demand. Operation of the electric vehicle is controlled based in part on the set of parameters, including the DC-DC current, the charging current, a first state of charge defined by the energy module, and a second state of charge defined by the power module.
Disclosed herein is an electric vehicle having a battery pack having an energy module adapted to generate a first current, and a power module connected in parallel to the energy module. At least one DC-to-DC converter is adapted to receive the first current from the energy module and transmit a DC-DC current to the power module. The electric vehicle includes a controller having a processor and tangible, non-transitory memory on which instructions are recorded for automated management of a set of parameters related to the battery pack, subject to a plurality of constraints. The power module is adapted to deliver a second current for powering a load in the vehicle, the energy module being adapted to selectively recharge the power module with a charging current after a predefined event of relatively high power demand. The set of parameters includes the DC-DC current, a first state of charge defined by the energy module, and a second state of charge defined by the power module, operation of the electric vehicle being controlled based in part on the set of parameters.
The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the best modes for carrying out the disclosure when taken in connection with the accompanying drawings.
Representative embodiments of this disclosure are shown by way of non-limiting example in the drawings and are described in additional detail below. It should be understood, however, that the novel aspects of this disclosure are not limited to the particular forms illustrated in the above-enumerated drawings. Rather, the disclosure is to cover modifications, equivalents, combinations, sub-combinations, permutations, groupings, and alternatives falling within the scope of this disclosure as encompassed, for instance, by the appended claims.
Referring to the drawings, wherein like reference numbers refer to like components,
The energy storage device 12 in
The design and/or composition of the power module 24 allows rapid movement of ions into and out of the electrode, thereby generating a higher power output. The design and/or composition of the energy module 22 reduces the movement of ions into and out of the electrode, thereby limiting power output. In other words, the energy module 22 is adapted to provide a sustained current for a longer period compared with the power module 24, and the power module 24 may provide a higher current over a short duration as compared with the energy module 22.
In one embodiment, the respective battery cells 18 in the power module include an electrode formed from a porous material and a thinner coating, while the respective battery cells 18 in the energy module include an electrode formed from a denser material and a thicker coating. In one embodiment, the voltage of the energy module 22 is about 800 volts (V) and the voltage of the power module 24 is between about 400 V to 600 V.
In one embodiment, the energy module 22 and the power module 24 employ batteries based on different chemistries. For example, the energy module 22 may include battery cells with the cathode material composed of nickel, cobalt oxide, and manganese. The power module 24 may include battery cells with the cathode material composed of lithium, iron, and phosphate. It is understood that the system 10 is not tied to a particular cell type, chemistry and configuration of the battery pack 14. In another embodiment, the energy module 22 and the power module 24 employ different battery designs, with the same chemistry.
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The controller C executes a control strategy that maintains full charge of the power module 24 using the DC-to-DC converter 26 after events of relatively high power demand. In other words, the power module 24 is recharged after each event of relatively high power demand, such that the power module 23 is able to fulfill the needs of the vehicle 20 when the next such event occurs. The event of relatively high power demand may be varied based on the application at hand. In one example, the predefined event is the initial acceleration and/or take-off of the electric vehicle 20. The predefined event may include the vehicle 20 being in tow mode and hauling or towing a load. As described below, the controller C manages individual energies from the power module 24 and the energy module 22 to meet power demand while meeting strict constraints in real-time, thereby increasing the life of the battery pack 14 and the DC-to-DC converter 26.
The maximum and minimum current that may be respectively taken from the power module 24 and energy module 22 varies over time as their respective charging status shifts.
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Per block 202 of
Proceeding to block 204, the controller C (via the prediction model 120) is adapted to receive input from an energy module observer (EMO) module 130 which transmits the voltage (V1) and state of charge (SOC1) of the energy module 22 (indicated by signal 132 in
Proceeding to block 208, the controller C (via execution of the predictive model 120) is adapted to calculate a desired DC-DC current 150 (IDC) that satisfies the plurality of constraints (“plurality of” omitted henceforth). The constraints on the desired DC-DC current 150 (IDC) include:
Here t is time, IDC is the DC-DC current, n is the number of phases of the DC-DC current, IC is the charging current 142, and I1,MIN and I1,MAX are the respective minimum and maximum values of the first current 110. The constraints on the desired DC-DC current 150 (IDC) include:
Here t is time, IDC is the DC-DC current, n is the number of phases of the DC-DC current, V1 and V2 are respective voltages of the energy module 22 and the power module 24, IL is a load current transmitted to the load 30 in the vehicle 20, and I2,MIN and I2,MAX are the respective minimum and maximum values of the second current 114.
The constraints include: IC(t)≤I1,MAX, where IC is the charging current 142, and I1,MAX is a maximum value of the first current 110. The constraints may further include: ΔIC(t)≤D, where ΔIDC is an incremental change in the desired DC-DC current 150 over time, and D is a predefined threshold. In one example, the predefined threshold is about 1 Amperes.
Advancing to block 210, the controller C is programmed to employ closed-loop feedback to minimize a difference (as shown at junction 154) between the desired DC-DC current 150 (calculated by in block 208) and the actual DC-DC current (signal 152) that is being transmitted by the DC-to-DC converter 26. The closed-loop control module available to those skilled in the art may be employed. Proceeding to block 212, operation of the vehicle 20 is controlled based on the set of parameters of the battery pack 14. Controlling operation of the vehicle 20 includes meeting the torque demand of the vehicle 20 through the battery pack 14 while meeting strict constraints in real-time.
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In summary, the system 10 allows generation of real-time constraints for using a battery model and predicting current limits of the energy module 22 and the power module 24. The respective battery cells 18 in the energy module 22 generally deliver sustained and continuous current over a long duration, while the respective battery cells 18 in the power module 24 generally deliver high current loads over a short duration at intermittent intervals. The system 10 allows for selective adjustment of the charge level of the power module 24. The DC-DC converter 26 allows charging of the power module 24 by the energy module 22.
As used herein, the terms ‘dynamic’ and ‘dynamically’ describe steps or processes that are executed in real-time and are characterized by monitoring or otherwise determining states of parameters and regularly or periodically updating the states of the parameters during execution of a routine or between iterations of execution of the routine.
The controller C of
Look-up tables, databases, data repositories or other data stores described herein may include various kinds of mechanisms for storing, accessing, and retrieving various kinds of data, including a hierarchical database, a set of files in a file system, an application database in a proprietary format, a relational database energy system (RDBMS), etc. Each such data store may be included within a computing device employing a computer operating system such as one of those mentioned above and may be accessed via a network in one or more of a variety of manners. A file system may be accessible from a computer operating system and may include files stored in various formats. An RDBMS may employ the Structured Query Language (SQL) in addition to a language for creating, storing, editing, and executing stored procedures, such as the PL/SQL language mentioned above.
The flowcharts shown in the FIG(S). illustrate an architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It will also be noted that each block of the block diagrams and/or flowchart illustrations, and combinations of blocks in the block diagrams and/or flowchart illustrations, may be implemented by specific purpose hardware-based systems that perform the specified functions or acts, or combinations of specific purpose hardware and computer instructions. These computer program instructions may also be stored in a computer-readable medium that can direct a controller or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instructions to implement the function/act specified in the flowchart and/or block diagram blocks.
The numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in each respective instance by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; about or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, disclosure of ranges includes disclosure of each value and further divided ranges within the entire range. Each value within a range and the endpoints of a range are hereby disclosed as separate embodiments.
The detailed description and the drawings or FIGS. are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, the embodiments shown in the drawings, or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims.